TRAINING TITLE:

BASIC HYDRAULICS AND

PNEUMATICS

Prepared By :Sintayehu Birhanu

1. Introduction

All machines require some type of power source and a

way of transmitting this power to the point of
operation.
The three methods of transmitting power are:
 Mechanical
 Electrical
 Fluid

 In this training we are going to deal with the third type

of power transmission which is the Fluid Power
Introduction
 Fluid power is the transmission of forces and
motions using a confined , pressurized fluid.

 Liquid or Gas is referred to as a fluid.

Accordingly, there are two branches of fluid
power; Pneumatics, and Hydraulics.

 Hydraulic systems use liquid to transfer force

from one point to another.
 Pneumatic systems use air to transfer force
from one point to another.
 Hydraulic vs pneumatic system

Hydraulic system Pneumatic system

It is almost incompressible compressible

preferred when precise position used where the presence of hydraulic oil
control is required could cause problems. (E.g. food processing)
It is expensive to build than It is less expensive to build
pneumatic
Advantage of Fluid power

 They eliminate the need for complicated

systems of gears, cams, and levers.
 Hydraulic systems are highly reliable and
efficient.
 Large forces can be controlled by much
smaller ones, and transmitted through small
lines.
 Used in a diverse range of applications.
Application of hydraulic in
NCSC
 Hydraulic system in our plant is used to
transmit power & produce motion.
 Used for lubrication of sliding and rotating
surface.
 Also used for cooling the system.
VRM triple gate valve

 This system is designed to control the open/

close action of three-gate mechanism of
vertical mill, including the actions of three air-
lock valves.
VRM Rollers tension system

 designed to control the action of tension

mechanism of vertical mill rollers used to
grind raw materials.
VRM Gearbox lubrication
system
 Used to lubricate gear & bearing and create
oil film b/n table & bearing.
 Consists of two low pressure pumps for
lubrication, one is main and the other is
standby.
 Also there are four high pressure pumps.
Kiln Hydraulic Thruster

 main function is to control and supervise the

axial position of the rotary kiln.
 system consists of a hydraulic pump unit (oil
tank, valves and a hydraulic pump), a
hydraulic controlled cylinder, and a LCP for
the electrical control.
Grate cooler hydraulic
station
 specially used in the driving of three-section
cooler beds, transport clinker materials on
the cooler bed.
 hydraulic cylinder which drives the moving
cooler bed to make advance and return
movement.
Cement mill sliding shoe

 It consists of two low pressure and two high

pressure pumps.
6KV motor & fan bearing
lubrication
 It consists of two low pressure pumps.
Application of pneumatic
system in NCSC
 Mainly used for bag filter lifting cylinder and
cleaning bags.
 It also used for controlling(opening & closing)
gate in the process line. E.g. homo silo
material discharging
 3. Fundamental laws of Hydraulics
 All hydraulic systems operate
following a defined relationship
between area, force and
pressure.

 Hydraulic systems use the

ability of a fluid to distribute an
applied force to a desired
location.
3.1 Pressure

 When a force (F) is applied on an

area (A) of an enclosed liquid, a
pressure (P) is produced as
shown in Fig.
 Pressure is the distribution of a
given force over a certain area.
 Pressure can be quoted in bar,
pounds per square inch (PSI) or
Pascal (Pa) .
Where
Force is in newtons (N) and
Area is in square meters (m2).
1 Pascal (Pa) =1 N/m2.
1 bar= 100,000 Pa= 105 Pa.
10 bar= 1 MPa (mega Pascals)
 There are three distinct ways in which
pressure is measured.
1) differential pressure:-measure the pressure
difference between two input ports.
2, gauge pressure:- the low pressure input port is
open to atmosphere ,so the pressure
transmitter indicates pressure above
atmospheric pressure.
3, absolute pressure:-the pressure transmitter
measuring pressure with respect to a vacuum.
 3.2 Pascal’s Law
 Pascal’s law states that:
“The pressure in a confined fluid
is transmitted equally to the
whole surface of its container”

 When force F is exerted on

area A on an enclosed liquid,
pressure P is produced. The
same pressure applies at
every point of the closed
system as shown in Fig. 3.1. Fig.3.1 Pascal’s law.
 3.2 Pascal’s Law
 Fig.3.2 shows that, if a downward force is
applied to piston A, it will be transmitted
through the system to piston B.
 According to Pascal’s law, the pressure at
piston A (P1) equals the pressure at piston B
(P2)

Piston A
Piston B

P1  P2 Fig.3.2 Power transmission

 3.2 Pascal’s Law
P1  P2
Fluid pressure is measured in terms of the force exerted per
unit area.

F
P
A F1
P1 
A1
F2
P2 
A2
F1 F2

A1 A2
The values F1, A2 can be calculated using the following formula:

A1  F2 A1  F2
F1  A2 
A2 , and F1
 3.2 Pascal’s Law
 Example 2
 In Fig 3.3, find the weight of
the car in N, if the area of
piston A is 0.0006m2, the area
of piston B is 0.0105 m2, and
the force applied on piston A is
Piston A
500 N. Piston

 Solution:
P1  P2 Fig 3.3

F1 F2 F1  A2 500  0.0105
 F2  F2 
A1 A2 A1 0.0006

F2  8750 N  8.75 kN
3.2 Pascal’s Law Piston A
Piston B
 Example 3
In Fig 3.3, if the weight of the car is 10,000 N, the diameter of
piston A is 0.01 m, and the force applied on piston A is 250 N.
Calculate the area of piston B.
 Solution:
1. Calculate the area of piston A, the piston shape is circular as
shown in Fig. 3.1, accordingly the area will be calculated using
the following formula.

2 2
D (0.01)
A1    3.14   0.0000785 m 2
4 4

F1  250 N F2  10,000 N
3.2 Pascal’s Law
 2. Apply Pascal’s law

F1 F
P1  P2 A1
 2
A2

 3. Use Pascal’s law to calculate the area of piston B

A1  F2
A2 
F1

2
(D )
A2    2  0.003140m 2
4

0.0000785  10,000
A2   0.00314m 2
250
 3.3 Liquid flow
3.3.1 Flow rate versus flow velocity
The flow rate is the volume of fluid that moves through the system in
a given period of time.
Flow rates determine the speed at which the output device (e.g., a
cylinder) will operate.
The flow velocity of a fluid is the distance the fluid travels in a given
period of time.
These two quantities are often confused, so care should be taken to
note the distinction. The following equation relates the flow rate and
flow velocity of a liquid to the size (area) of the conductors (pipe,
tube or hose) through which it flows.

Q =V x A
Where:
Q= flow rate ( m³ /s )
V= flow velocity (m / s )
A= area (m² )
3.3 Liquid flow

This is shown graphically in Fig. 3.4 Arrows

are used to represent the fluid flow. It is
important to note that the area of the pipe or
tube being used.

Q, V
A

Fig.3.4 Flow velocity and flow rate

3.3 Liquid flow

 Example 4
A fluid flows at a velocity of 2 m/s through a pipe with
a diameter of 0.2 m. Determine the flow rate.
Solution:
1. Calculate the pipe area
2
D (0.2) 2
A  3.14   0.0314 m 2
4 4

2. Calculate the flow rate

m3
Q V  A Q  2  0.0314  0.0628
Sec
3.3.2 The continuity equation
Hydraulic systems commonly have a pump that
produces a constant flow rate. If we assume that the
fluid is incompressible (oil), this situation is referred to
as steady flow. This simply means that whatever
volume of fluid flows through one section of the system
must also flow through any other section. Fig. 3.5 shows
a system where flow is constant and the diameter varies

A1 V1
A2 V2

Q1 Q2

Fig.3.5 Continuity of flow.

 3.3.2 The continuity equation

The following equation applies in this system:

Q1  Q2
Therefore,

V1  A1  V2  A2
The following example illustrates the significance
of the continuity equation shown above.
 3.3.2 The continuity equation
 Example 5
 A fluid flows at a velocity of 0.2 m/s at point 1 in
the system shown in Fig. 3.5. The diameter at
point 1 is 50mm and the diameter at point 2 is 30
mm. Determine the flow velocity at point 2. Also
determine the flow rate in m³ /s .
 1. Calculate the areas
2
D (50  10 3 ) 2
A1    1  3.14 *  1.963  10 -3 m 2
4 4
2
D2 (30 10 3 ) 2
A2     3.14 *  7.068  10 - 4 m 2
4 4
 3.3.2 The continuity equation

2. Calculate the velocity at point 2

Q1  Q2
Therefore,
V1  A1  V2  A2
A1 1.963 10 -3
V 2  V1   0.2   0.55m / s
A2 7.068 10 -4

3. Calculate the flow rate in m³ /s

Q1  V1  A1  0.2  1.963  10 -3  3.926  10 4 m 3 s

3.3.2 The continuity equation
The example shows that in a system with a
steady flow rate, a reduction in area (pipe size)
corresponds to an increase in flow velocity by
the same factor. If the pipe diameter increases,
the flow velocity is reduced by the same factor.
This is an important concept to understand
because in an actual hydraulic system, the pipe
size changes repeatedly as the fluid flows
through hoses, fittings, valves, and other
devices.
 4. Hydraulic system components
 All industrial hydraulic systems consist of the following basic components
 Power input device:
The pump and motor together are called the power input device; the
pump provides power to the hydraulic system by pumping oil from the
reservoir/tank. The pump’s shaft is rotated by an external force which is
most often an electric motor as illustrated in Fig 4.1.

Control device
Power input device Tank
Valve

Pump Liquid
Motor

Pipes or tubes

Power output device

Actuator
 4.Hydraulic system components
 Control device: Valves control the direction, pressure,
and flow of the hydraulic fluid from the pump to the
actuator/cylinder.
 Power output device: The hydraulic power is converted
to mechanical power inside the power output device. The
output device can be either a cylinder which produces
linear motion or a motor which produces rotary motion.
 Liquid: the liquid is the medium used in hydraulic systems
to transmit power. The liquid is typically oil, and it is
stored in a tank or reservoir.
 Conductors: The conductors are the pipes or hoses
needed to transmit the oil between the hydraulic
components.
4.1 Hydraulic power pack
 The hydraulic power pack combines the pump,
the motor, and the tank. The hydraulic power
pack unit provides the energy required for the
hydraulic system. The parts of the hydraulic
power pack unit are shown in Fig. 4.2.

Fig. 4.2 The main parts of the hydraulic power pack

 4.2 Hydraulic symbols
 The way hydraulic components direct and
control liquid around a circuit can be
complex.
(a) Electric motor
 This would cause difficulty for one engineer
explaining to another engineer how the
circuit works.
 A common form of representing
components and circuits is used to more (b) Hydraulic pump
easily explain what is happening.
 This form of representation uses common
symbols to represent components and the
ways in which they are connected to form (c) Tank or reservoir

circuits. Fig. 4.3 shows some of the

components’ symbols used in hydraulics.
 The symbols don’t show the component
construction, or size, however, it is a (d)Pressure relief valve

standard form that is used by all engineers Fig.4.3 (a) Electric motor. (b) Hydraulic pump.
(c) Tank or reservoir. (d) Pressure relief valve.
to represent that specific component.
Power Pack Symbols
 The simplified and detailed symbols of the
hydraulic power pack are shown in Fig. 4.4.

(a) Simplified

(b) Detailed
Fig.4.4: (a) Simplified symbol of the hydraulic power pack.
Hydraulic Pump

 Provide the Flow needed to transmit power

from a prime mover to a hydraulic actuator.
 The hydraulic pump mainly categorized in to
two.
A, Non- Positive displacement pump
B, Positive displacement pump
Non- Positive displacement
pump:
 These pumps are also known as hydro-
dynamic pumps.
 In these pumps the fluid is pressurized by the
rotation of the propeller and the fluid
pressure is proportional to the rotor speed.
 Centrifugal pump is common type of this
pump.
Positive displacement pump:

 These pumps deliver a constant volume of

fluid in a cycle.
 The discharge quantity per revolution is fixed
in these pumps and they produce fluid flow
proportional to their displacement and rotor
speed.
5.Control valve

 This Valves control the direction, pressure,

and flow of the hydraulic fluid from the pump
to the actuator/cylinder.
 A valve is represented by a square for each
of its switching positions.
 Ports of a valve are shown on the outside
of boxes in normal un operated or initial
position.
Control valve

 There are basically three types of valves

employed in hydraulic systems:
1. Directional control valves
2. Flow control valves
3. Pressure control valves
5.1 Directional control
valves
 Direction control valves are used to control
the distribution of energy in a fluid power
system.
 They provide the direction to the fluid and
allow the flow in a particular direction.
Based on type of
construction classified as:
 Poppet valve
 spool valve
Poppet valve

 In poppet valves, a ball, cone or a disk is

pressed against a seat area to act as a sealing
element. Valves of this type provide a very
efficient seal.
Spool valve

 Spool (or slide) valves are constructed with

a spool moving horizontally within the
valve body.
 This type of valve cannot provide a perfect
seal, which means that there is always a
certain oil leakage.
Based on number of port and
switching position classified
as:
1, 2 port 2 position valve
2, 3 port 2 position valve
3, 4 port 2 position valve
4, 5 port 2 position valve
6, 4 port 3 position valve
2/2-way valve
 The 2/2-way valve has a working port A, a supply
port P and a leakage-oil port L. In the case of the
valve shown here, of slide design, flow from P to
A is closed in the normal position.
 The 2/2-way valve is actuated and the passage
from P to A is open.
3/2-way valve
 The 3/2-way valve has working port A, a supply port P
and a tank port T. Volumetric flow can be routed from the
supply port to the working port or from the working port
to the tank port. The third port in each case is closed. In
the normal position shown, P is closed and flow released
from A to T.
 The 3/2-way valve is actuated; flow is released from P
to A, the outlet T is closed.
4/2-way valve
 The 4/2-way valve has two working ports A and
B, a supply port P and a tank port T. The supply
port is always connected to one of the working
ports, while the second working port is routed to
the tank. In the normal position, there is flow
from P to B and from A to T.
 4/2-way valves with two pistons do not require a
leakage-oil port. The 4/2-way valve is actuated,
and there is flow from P to A and from B to T.
4/3-way valve
 From the logic point of view, 4/3-way valves are
4/2- way valves with an additional mid-position.
There are various versions of this mid-position (in
the mid-position in the example shown, the
supply port P is directly connected to the tank T.
 In the switching position shown, there is flow
from P to B and from A to T.
Based on actuation mechanism
classified as:
 Manual actuation
 Mechanical actuation
 Solenoid actuation
 Hydraulic actuation
Manual actuation

 In this type, the spool is operated manually.

 Manual actuators are hand lever, push button
and pedals etc.
Mechanical actuation

 The DCV spool can be operated by using

mechanical elements such as roller and cam,
roller and plunger and rack and pinion etc. In
these arrangements, the spool end is of roller
or a pinion gear type. The plunger or cam or
rack gear is attached to the actuator.
 Thus, the mechanical elements gain some
motion relative to the actuator (cylinder
piston) which can be used for the actuation.
Solenoid actuation

 The solenoid actuation is also known as electrical

actuation.
 The energized solenoid coil creates a magnetic force
which pulls the armature into the coil. This movement of
armature controls the spool position.
 The main advantage of solenoid actuation is its less
switching time.
Hydraulic actuation
 This type actuation is usually known as pilot-
actuated valve.
 In this type of actuation, the hydraulic pressure is
directly applied on the spool. The pilot port is
located on one end of the valve. Fluid entering
from pilot port operates against the piston and
forces the spool to move forward.
 The needle valve is used to control the speed of
the actuation.
5.2 Flow control valves
 . A flow control valve can regulate the flow or
pressure of the fluid. The fluid flow is
controlled by varying area of the valve
opening through which fluid passes.
 The fluid flow can be decreased by reducing
the area of the valve opening and it can be
increased by increasing the area of the valve
opening.
5.2.1 One-way flow control
valve
 The one-way flow control valve is a
combination of an orifice or throttle valve and
a non-return valve. In the closed direction
shown of the non- return valve, the volumetric
flow passes via the variable throttle gap, which
creates a considerable resistance.
 Speed reduction can be achieved by using a
one- way flow control valve in conjunction with
a pressure relief valve or a variable-delivery
pump.
Continue…

 In the reverse direction, from B to A, flow is

unrestricted, since the ball in the one- way flow
control valve allows free flow (non- return
function).
5.2.2 two-way flow control
valve
 This type of Flow control valves have the
task of providing constant volumetric flow
independently of pressure changes at the
inlet or outlet of the valve.
 This is achieved firstly by means of an
adjustable restrictor which is set to the
desired volumetric flow.
Continue…

 In order to keep the pressure drop across the

throttle point constant, a second regulating
restrictor (pressure compensator) is also
required.
5.3 Pressure control valve

 The pressure relief valves are used to protect the

hydraulic components from excessive pressure.
This is one of the most important components
of a hydraulic system and is essentially required
for safe operation of the system.
 Its primary function is to limit the system
pressure within a specified range. It is normally a
closed type and it opens when the pressure
exceeds a specified maximum value by diverting
pump flow back to the tank.
5.3.1 Direct type of relief
valve
 This type of valves has two ports; one of
which is connected to the pump and another
is connected to the tank.
Continue…

 It consists of a spring chamber where poppet

is placed with a spring force. Generally, the
spring is adjustable to set the maximum
pressure limit of the system.
 The poppet is held in position by combined
effect of spring force and dead weight of
spool. As the pressure exceeds this combined
force, the poppet raises and excess fluid
bypassed to the reservoir (tank).
5.3.2 Unloading Valve
 This valve consists of a control chamber with
an adjustable spring which pushes the spool
down.
 The valve has two ports: one is connected to
the tank and another is connected to the
pump.
5.4. Actuator

 An actuator is a device, which converts fluid

power into mechanical force and motion.
 Cylinders, motors, and turbines are the
most common types of actuating devices
used in fluid power systems.
 An actuating cylinder is a device, which
converts fluid power to linear or straight-line
force and motion.
Single acting cylinder
 In the case of a single acting cylinder, only the
piston side is pressurized with hydraulic fluid.
 The fluid, which flows into the piston chamber,
causes a pressure to build up the surface of the
piston. The piston travels into its forward end
position. The return stroke is affected by a
spring, the dead weight of the piston rod or an
external load.
 Double acting cylinder
 In the case of double acting cylinders, both
piston surfaces can be pressurized. A working
movement can thus be performed in both
directions. With double acting cylinders with
a single-sided piston rod, different forces and
speeds are obtained on the advance and
return strokes due to the difference in area
between the piston surface and annular
piston surface.
6.Graphical representation
of hydraulic
 The hydraulic and pneumatic elements
such as cylinders and valves are connected
through pipelines to form a hydraulic.
 It is difficult to represent the complex
functioning of these elements using sketches.
Therefore graphical symbols are used to
indicate these elements.
Symbols for ports

Port Letter system Number system

Pressure port P 1

Working port A 4

Working port B 2

Exhaust port R 5

Exhaust port S 3

Pilot port Z 14

Pilot port Y 12
 Graphical symbols of
 
hydraulic    

SYMBOL DESIGNATION EXPLANATION

 

Energy supply

     
 
One direction and two
Two direction of rotation
With constant displacement
Hydraulic pump
 
  One direction and two
 

Two direction of rotation

With variable displacement

Direction control valves (DCVs)

Two closed ports in the closed

2/2 way valve neutral position and flow
during actuated position
 Continue…
In the first position flow takes
3/2 way valve place to the cylinder
In the second position flow takes
out of the cylinder to the
exhaust (Single acting cylinder)
For double acting cylinder all
4/2 way valve the ports are open

4/3 way valve Two open positions and

one closed neutral position

Direction control valve actuation methods

General manual
actuation

Roller lever actuation